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Author Topic: Dia. Mag. Alternator  (Read 168414 times)

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #225 on: July 22, 2011, 01:36:03 AM »
Here are the Threaded Inserts, and the new Mini Studs.
On the left you can see the T-Slot Nut with the Threaded
insert installed.  There are slots in the top of the threaded
insert for a screwdriver.  Don't do it...  Instead I installed
them with a the hardened stud and flange nut.  Using a
flathead screw driver only messed up the slotted edges,
and I cross threaded one of them.  Using the Stud and
Flange Nut allowed me to use a wrench instead of a screw
driver.  The wrench allowed a much easier insertion.

In the center is the new 1/4 inch Mini Stud T-Slot Nut,
and on the right is a 1/2 inch Stud in a T-Slot Nut.  Also
you can see the difference in the Flange Nuts...

Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #225 on: July 22, 2011, 01:36:03 AM »

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #226 on: July 22, 2011, 02:47:27 AM »
Now I have the wire form plates clamped on the table and am
cutting the straight line.  There are 3 clamps holding the work
piece to the table, so its very rigid.  I use the X/Y screws to
line up the cuts, cut a series of holes on the Y axis, and then
run the side mill up and down the slot on the Y axis a couple
of times, adjusting the X axis to cleanup the scallops...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #227 on: July 23, 2011, 07:31:13 PM »
Cut the outer radius of the wire form this morning, and started
cutting the slots.  Plan to finish the slots this afternoon and
do the inner radius.  The slots are a lot cleaner when you have
both ends closed at the time of cutting.  After all the slots are
cut I'll open the inside end (inside radius)...

Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #227 on: July 23, 2011, 07:31:13 PM »
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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #228 on: July 24, 2011, 05:27:21 PM »
OK, got the Wire Form Plates cutout, rough cut anyway.
Now starting on the Bearing Mounting Plates.

Offline Cap-Z-ro

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Re: Dia. Mag. Alternator
« Reply #229 on: July 24, 2011, 08:16:42 PM »

Kinda reminds me of the layout of the Model T magneto Z...you are really putting a lot into this...hope you find success.

Regards...


Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #229 on: July 24, 2011, 08:16:42 PM »
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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #230 on: July 25, 2011, 12:15:26 AM »
Thanks Cap,
Yeah, its kinda like a Magneto...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #231 on: July 25, 2011, 03:05:13 AM »
Since I already had the Radius Jig setup I decided to cut the
radius on the Bearing Plates first.  Then got the Straight Line Jig
setup and started cutting the spars.  This last cut I made is
beautiful.  I cut it wide with a series of end cuts.  Then went back
and side milled the whole line X axis minus 30 mils or so.  Best
slot cut Evar!  Whoo Hoo!

Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #231 on: July 25, 2011, 03:05:13 AM »
Sponsored links:




Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #232 on: July 25, 2011, 04:05:56 AM »
Yeah, I think the new process is working out well...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #233 on: July 25, 2011, 05:42:56 PM »
There, got the Wire Form Plates cleaned up.  Together with the
assembly studs and the Wire Form Plate spacers they form the
Stator for DiaMag8.  The Bearing Mounting Plates are still clamped
to the Milling Table.  Got a few more cuts there, and then we
can assemble everything and start checking it out...

Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #233 on: July 25, 2011, 05:42:56 PM »
3D Solar Panels

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #234 on: July 26, 2011, 02:58:00 AM »
Oh, La la...  Schweet!

DiaMag8 is fabricated...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #235 on: July 27, 2011, 01:59:38 AM »
Just now got the Rotor Magnets installed.  That was a sticky situation.
I used 5 minute epoxy.  Got all the magnet lined up on the fridge.
Then spread a thin layer of epoxy on the rotor.  Added a pair of
magnets at a time.  When the ring was complete, I spent the rest
of the cure time cleaning up the goop, and aligning magnets.

After it was cured I fit it in the stator.  The stator was a little off,
and I needed to file down some high spots.  Its still a little funny,
but the rotor spins.  I'll clean it up a little more tomorrow...

Free Energy | searching for free energy and discussing free energy

Re: Dia. Mag. Alternator
« Reply #235 on: July 27, 2011, 01:59:38 AM »
3D Solar Panels

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #236 on: July 29, 2011, 01:50:41 AM »
I had made some holes in periphery of the stator plates.
They accommodate the wire management dowels.  They
help guide the windings where they need to go.  Also
needed to use some spacers to add phatness to the
dowels.  The first winding looks pretty good.  I'll be getting
some more practice in the near future....

I also added the vinyl inserts in the slots, like on DiaMag7,
to isolate the windings from the aluminum parts...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #237 on: July 29, 2011, 10:07:25 PM »
OK, got the stator wound.  It probably took a full day to wind it.
I want to find a better way to do the next one.  The wire management
sticks dowels moved around a lot.  I think the wire looks kind of
sloppy around the periphery.  In the slots it looks great.  Some of my
vinyl inserts are dragging on the rotor.  I'll use a side cutter to trim
out the extra bits.  Also got a shot of it assembled...

Offline Cap-Z-ro

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Re: Dia. Mag. Alternator
« Reply #238 on: July 29, 2011, 11:17:29 PM »

Certainly looks mean Z...hope its a success for you.

Regards...


Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #239 on: July 30, 2011, 12:38:45 AM »
Hey Cap,
Like angry, sinister?

Insert righteous political outrage here...

If you ask my wife, its a toy, that and all the tools, just toys...

 

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